Method for manufacturing a laminated core

Abstract

A laminated core (4) formed by layering a plurality of first core sheets (11) and second core sheets (219 which have been punched out from electrical steel (100), wherein the first core sheets (11) are formed in a manner such that the sheet thickness thereof increases from one end toward the other end, the second core sheets (21) are formed in a manner such that the sheet thickness thereof increases from the other end toward the one end, and the first core sheets (11) and the second core sheets (21) are layered so as to alternate with one another every pre-set number of sheets.

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a laminated core It relates to.

Background Art

[0002] In recent years, there has been a demand for miniaturization and high output in rotating electrical machines such as electric motors and generators. The armature core used in a rotating electrical machine is composed of a laminated core in which core plates formed from electromagnetic steel sheets are laminated. Thus, it is widely known that by suppressing eddy currents generated in the armature core, high efficiency can be achieved. Also, by integrating the divided laminated cores to form an armature core, it is widely known that the winding occupation ratio can be increased to achieve high efficiency.

[0003] Here, since the electromagnetic steel sheet used for the laminated core is a thin plate rolled between rolling rolls, it is common for the plate thickness to have a deviation (hereinafter referred to as plate thickness deviation) due to the characteristics and state of the rolling rolls. When the electromagnetic steel sheet becomes thinner, the number of laminated sheets increases, and thus there is a problem that the inclination of the laminated core due to the plate thickness deviation becomes large. As a measure for reducing the plate thickness deviation, a method of dividing and overlapping the electromagnetic steel sheet before punching has been disclosed (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0004] The present disclosure discloses a technique for solving the above problems, which can be produced inexpensively and stably to a method for manufacturing a laminated core with the aim of obtaining.

Summary of the Invention

Problems to be Solved by the Invention

[0005] Conventional laminated cores, rotating electrical machines, manufacturing methods of laminated cores, and manufacturing methods of rotating electrical machines have a problem that since a process of cutting the electromagnetic steel sheet and a process of overlapping are required before punching, the press device becomes large and the equipment cost increases.

[0006] This application discloses a technology for solving the above problems, and aims to obtain a laminated core, a rotating electrical machine, a method for manufacturing the laminated core, and a method for manufacturing the rotating electrical machine that can be produced inexpensively and stably.

Means for Solving the Problems

[0007] The present disclosure The provided method for manufacturing a laminated core is a method for manufacturing a laminated core formed by laminating a plurality of first core plates and second core plates punched from electromagnetic steel sheets, wherein the first core plate is formed such that the plate thickness increases from one side to the other side, the second core plate is formed such that the plate thickness increases from the other side to the one side, the first core plate and the second core plate are alternately laminated for each preset number to form a laminated core, a punching step of punching the first core plate and the second core plate from electromagnetic steel sheets having different plate thicknesses in the plate width direction, an alignment step of alternately laminating the first core plate and the second core plate for each preset number to form an aligned core plate group, and a fixing step of fixing the laminated core in the lamination direction of the core plate group. In the punching step of the method for manufacturing a laminated core, the punching is performed by inverting the tooth tip sides of the first core plate and the second core plate in the plate width direction of the electromagnetic steel sheet, or by inverting the tooth tip sides of the first core plate and the second core plate in the rolling direction of the electromagnetic steel sheet. In the alignment step, the first core plate and the second core plate are respectively fed into different inlets, and the tooth tip sides of the first core plate and the second core plate are aligned to form the core plate group before reaching an outlet where the first core plate and the second core plate merge. Also, The present disclosure the provided method for manufacturing a laminated core is A method for manufacturing a laminated core formed by laminating a plurality of first core plates and second core plates punched from electromagnetic steel sheets, The first core plate is formed such that the plate thickness increases from one side to the other side, The second core plate is formed such that the plate thickness increases from the other side to the one side, The first core plate and the second core plate are alternately laminated for each preset number to form a laminated structure, A punching step of punching the first core plate and the second core plate from an electromagnetic steel sheet having different plate thicknesses in the plate width direction, An aligning step of alternately laminating the first core plate and the second core plate for each preset number to form an aligned core plate group, A fixing step of fixing in the lamination direction of the core plate group, In the punching step, in the method for manufacturing a laminated core, the teeth tip sides of the first core plate and the second core plate are inverted and punched in the plate width direction of the electromagnetic steel sheet, or the teeth tip sides of the first core plate and the second core plate are inverted and punched in the rolling direction of the electromagnetic steel sheet, The aligning step is as follows: A rotating plate having a through hole that rotates around a rotation center and connects to the paths of the first core plate and the second core plate punched in the punching step to accommodate the first core plate and the second core plate, In synchronization with the punching step, the rotating plate rotates by an angle corresponding to the through hole in the paths of the first core plate and the second core plate, and the first core plate and the second core plate are stored and laminated in the through hole of the rotating plate, When the paths of the first core plate and the second core plate of the rotating plate are not connected by the through hole, the laminated first core plate and second core plate are discharged from the through hole of the rotating plate to form the core plate group. is as follows.

Advantages of the Invention

[0008] To the method for manufacturing a laminated core of the present disclosure According to this, It can be produced inexpensively and stably. to a method for manufacturing a laminated core It can be obtained.

Brief Description of the Drawings

[0009]

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Mode for Carrying Out the Invention

[0010] Embodiment 1. FIG. 1 is a perspective view showing the configuration of the laminated core according to Embodiment 1. FIG. 2 is a cross-sectional view showing the configuration of the rotating electrical machine using the laminated core shown in FIG. 1. FIG. 3 is a flowchart showing the manufacturing method of the laminated core shown in FIG. 1. FIGS. 4 and 5 are diagrams for explaining the manufacturing method of the laminated core shown in FIG. 1. FIG. 4A is a plan view of the electromagnetic steel sheet, and FIG. 4B is a diagram showing the thickness of the electromagnetic steel sheet as viewed from the direction of arrow W1 in FIG. 4A.

[0011] FIG. 5A is a plan view showing the configuration of the first core plate, and FIG. 5B is a diagram showing the thickness of the first core plate shown in FIG. 5A as viewed from the direction of arrow W2. FIG. 5C is a plan view showing the configuration of the second core plate, and FIG. 5D is a diagram showing the thickness of the second core plate shown in FIG. 5C as viewed from the direction of arrow W3. FIG. 6 is a perspective view showing the state where a coil is installed in the laminated core shown in FIG. 1. FIGS. 7 and 8 are perspective views showing the configurations of other laminated cores according to Embodiment 1.

[0012] In FIG. 2, the rotating electrical machine 10 includes a rotor 122 which is a rotating part, a stator 123 that generates a force for rotating the rotor 122, and a frame 124 for housing the rotor 122 and the stator 123. The stator 123 and the rotor 122 are arranged to face each other with an air gap 107 therebetween. The stator 123 is formed by arranging a plurality of laminated cores 4, in which an insulator (not shown) and a coil 9 (see FIG. 6) are installed, in an annular shape. In the rotating electrical machine 10, the axial direction is defined as T1 and the radial direction is defined as T2.

[0013] In FIG. 1, the laminated core 4 is formed by alternately laminating a first core plate 11 and a second core plate 21 in the lamination direction T1 to form a core plate group 40 having a length set in advance in the lamination direction T1. The lamination direction T1 of the laminated core 4 is the same as the axial direction T1 of the rotating electrical machine 10. The laminated core 4 is fixed by an adhesive portion 5 formed over the lamination direction T1 on a part of the side surface of the core plate group 40.

[0014] The first core plate 11 and the second core plate 21 are formed by punching out from an electromagnetic steel sheet 100 which will be described later. As shown in FIG. 5, the first core plate 11 is formed such that the plate thickness increases from one side to the other side, here from one side in the radial direction T2 to the other side. The second core plate 21 is formed such that the plate thickness increases from the other side to the one side, here from the other side in the radial direction T2 to the one side. The details of the first core plate 11 and the second core plate 21 will be described in the manufacturing method of the laminated core 4. Also, in FIG. 1, for the sake of convenience, the plate thickness is shown to be the same. Also, the points where the plate thickness is shown to be the same for the sake of convenience are the same in other FIGS. 6, 7, and 8.

[0015] As shown in FIG. 4A, each direction of the electromagnetic steel sheet 100 from which the first core plate 11 and the second core plate 21 are punched will be described as the rolling direction X and the sheet width direction Y. And here, as shown in FIG. 4B, for example, a case where a sheet thickness deviation occurs in which the sheet thickness Z increases from one end side to the other end side in the sheet width direction Y of the electromagnetic steel sheet 100 will be described. The electromagnetic steel sheet 100 is a thin sheet rolled between rolling rolls. A thin sheet is generally a very thin sheet with a thickness of 0.5 mm or less.

[0016] Due to such a thin sheet, it is common for a sheet thickness deviation to occur in the sheet thickness Z in the sheet width direction Y due to the characteristics and conditions of the rolling rolls and the like. Note that since the same applies to each of these directions and the sheet thickness deviation in the following description, the description thereof will be omitted as appropriate. Note that various cases can be considered as examples of the sheet thickness deviation, but for the sake of convenience of explanation, the example will be described. Also, in each figure, in order to clarify the sheet thickness Z, the sheet thickness Z is exaggeratedly illustrated.

[0017] Next, a method for manufacturing the laminated core and the rotating electrical machine according to the first embodiment configured as described above will be described. First, by pressing, in the electromagnetic steel sheet 100 having a sheet thickness deviation as shown in FIG. 4A, at different positions in the sheet width direction Y, the first core plate 11 is punched at the first position 61 and the second core plate 21 is punched at the second position 62 so that the tooth tip sides 64 of the first core plate 11 and the second core plate 21 are inverted in the sheet width direction Y (punching step ST1 in FIG. 3).

[0018] And the first core plate 11 punched at the first position 61 is formed as shown in FIG. 5A. And as shown in FIG. 5B, the first core plate 11 is formed such that the sheet thickness Z increases from the tooth tip side 64 toward the core back side 63. That is, the first core plate 11 is formed such that the sheet thickness Z increases from one side in the radial direction T2 of the rotating electrical machine 10, here, from the tooth tip side 64, to the other side, here, toward the core back side 63.

[0019] On the other hand, at the second position 62, the second core plate 21 punched out so as to have a tooth tip side 64 reversed from the tooth tip side 64 of the first core plate 11 is formed as shown in FIG. 5C. Then, as shown in FIG. 5D, the second core plate 21 is formed such that the plate thickness Z increases from the core back side 63 toward the tooth tip side 64. That is, the second core plate 21 is formed such that the plate thickness Z increases from the core back side 63, which is the other side in the radial direction T2 of the rotating electrical machine 10, toward the tooth tip side 64, which is one side here. Note that the radial direction T2 shown in FIG. 5 indicates the direction at the center position in the circumferential direction T3 of each core plate 11, 21.

[0020] If only the first core plate 11 (or only the second core plate 21) formed in this way is laminated, a difference in thickness accumulates between the core back side and the tooth tip side in the radial direction of the rotating electrical machine. Therefore, the obtained laminated core has a shape that is curved and inclined in the core radial direction when viewed from the side of the laminated core. Since this phenomenon becomes larger in proportion to the number of laminated core plates, it becomes more prominent as the stack thickness of the laminated core increases or as the thickness of the electromagnetic steel sheet decreases because the number of laminated thin core plates constituting the laminated core increases.

[0021] When a rotating electrical machine is manufactured using such an inclined laminated core, the air gap between the laminated core and the rotor becomes non-uniform, the magnetic attraction force varies depending on the rotation angle, and the motor performance deteriorates. Further, when an insulator and a coil are attached to the laminated core and when the stator is attached to the frame, the possibility of interference with jigs and devices also increases, deteriorating the productivity in manufacturing the rotating electrical machine.

[0022] In contrast, in the first embodiment, as shown in FIG. 5, one first core plate 11 and one second core plate 21, each having a reverse tendency in the plate thickness Z between the core back side 63 and the tooth tip side 64, are alternately laminated one by one to form a core plate group 40 (alignment step ST2 in FIG. 3). Therefore, in the laminated core 4, the difference in the plate thickness Z between the first core plate 11 and the second core plate 21 does not accumulate. Accordingly, the difference in the dimension in the lamination direction T1 between the core back side 63 and the tooth tip side 64 of the laminated core 4 becomes small, the degree of inclination of the laminated core 4 can be suppressed, and the motor performance when manufacturing the rotating electrical machine 10 can be improved. Further, due to the nature of the rolling process, there is almost no deviation in the plate thickness in the rolling direction X. Therefore, the influence of the position in the rolling direction X on the punching position of each core plate 11, 21 is sufficiently small compared to the plate width direction Y.

[0023] Next, in order to fix the aligned and laminated first core plate 11 and second core plate 21 of the laminated core 4, a part of the side surfaces of the first core plate 11 and the second core plate 21 are adhered with an adhesive to form and fix an adhesive portion 5 (fixing step ST3 in FIG. 3).

[0024] Generally, as a method for fixing laminated core plates to each other, there is a method of caulking the core plates in the axial direction. In this method, since the electromagnetic steel plates are electrically short-circuited in the lamination direction at the fixed portion, there is a problem that eddy currents are generated and the efficiency deteriorates. Further, since residual stress is generated in the caulked portion, there is also a problem that the hysteresis loss increases and the efficiency of the rotating electrical machine deteriorates.

[0025] In contrast, as shown in FIG. 1, by fixing the laminated core 4 with the adhesive portion 5, electrical short-circuiting is eliminated and residual stress can also be reduced, so that an efficient laminated core 4 can be obtained. Next, as shown in FIG. 6, a coil 9 is formed on the laminated core 4. Next, a stator 123 formed by annularly arranging a plurality of laminated cores 4 on which the coil 9 is formed is installed in the frame 124, and the rotor 122 is arranged to face via an air gap 107 to form a rotating electrical machine 10 (FIG. 2).

[0026] Note that, as shown in FIG. 1, the laminated core 4 shown in the above-described Embodiment 1 shows an example in which the first core plate 11 and the second core plate 21 are alternately laminated one by one in the lamination direction T1. However, the present invention is not limited to this. For example, as shown in FIG. 7, a case where the first core plate 11 and the second core plate 21 are alternately laminated in the lamination direction T1 by a plurality of preset sheets (FIG. 7 shows an example of laminating five sheets at a time) is also conceivable. Similar to the above-described Embodiment 1, the laminated core 4 and the rotating electrical machine 10 can be formed. Note that, based on information such as the cycle time of the apparatus for manufacturing the laminated core 4 or the profile of the thickness deviation of the electromagnetic steel sheet 100, the optimum number of laminated sheets of the first core plate 11 and the second core plate 21 may be appropriately selected to configure the laminated core 4.

[0027] Further, as shown in FIG. 1, the laminated core 4 shown in the above-described Embodiment 1 shows an example in which the adhesive portion 5 is formed and fixed with an adhesive in the fixing step ST3. However, the present invention is not limited to this. For example, as shown in FIG. 8, in order to fix the aligned and laminated first core plate 11 and second core plate 21 of the laminated core 4, a part of the side surfaces of the first core plate 11 and the second core plate 21 is welded to form a welded portion 8 and fixed. This case is also conceivable, and the laminated core 4 and the rotating electrical machine 10 can be formed in the same manner as in the above-described Embodiment 1. Note that, similar to caulking, there is a problem that the electromagnetic steel sheet is short-circuited in the lamination direction at the welded portion, eddy currents are generated, and the efficiency deteriorates. However, since it is possible to increase the fixing strength compared to the adhesive portion, it is an effective means when strong fixing between laminations is required.

[0028] Further, in the above-described Embodiment 1, an example in which the fixing step ST3 is performed after the alignment step ST2 is shown. However, the alignment step ST2 and the fixing step ST3 may be performed simultaneously. For example, when punching out each core plate 11, 21 from the electromagnetic steel sheet 100, a caulking portion is created, and by applying pressure between the laminations, the laminations can be fixed by caulking while aligning each core plate 11, 21.

[0029] By doing so, the alignment process ST2 and the fixing process ST3 are integrated, the manufacturing process is shortened, and the manufacturing costs of the laminated core 4 and the rotating electrical machine 10 are reduced. Further, instead of caulking, the layers may be fixed by applying or spraying an adhesive between the layers and pressing the layers together. By doing so, the problem that the electromagnetic steel sheets short-circuit in the lamination direction due to caulking, generating eddy currents and deteriorating efficiency, can be solved, and an efficient laminated core can be obtained.

[0030] Also, in the above-described Embodiment 1, an example in which the bonding portion 5 or the welding portion 8 is formed as the fixing process ST3 has been shown, but the present invention is not limited thereto. When the bonding portion or the welding portion is not formed, as shown in FIG. 6, by installing the coil 9, it is also conceivable to manufacture as the fixing process ST3 for fixing between the layers.

[0031] According to the laminated core of Embodiment 1 configured as described above, a laminated core formed by laminating a plurality of first core plates and second core plates punched out from electromagnetic steel sheets, the first core plate is formed such that the plate thickness increases from one side to the other side, the second core plate is formed such that the plate thickness increases from the other side to the one side, the first core plate and the second core plate are alternately laminated for each preset number, Also, according to the rotating electrical machine of Embodiment 1 configured as described above, it includes a stator formed by arranging a plurality of the above-described laminated cores in an annular shape, and a rotor arranged to face the stator with an air gap therebetween, When the first core plate and the second core plate are laminated, the difference in dimensions in the lamination direction that occurs is not accumulated and is reduced, and a laminated core with a stable posture and little inclination can be obtained. This is because even if a large number of the first core plates and the second core plates are laminated, the influence of the plate thickness deviation can be minimized, and a laminated core with a small inclination can be stably obtained using inexpensive equipment. As a result, the air gap between the stator and the rotor formed using the laminated core is made uniform, variations in magnetic attraction force due to the rotation angle are suppressed, and the motor performance is improved. In addition, when attaching the insulator and the coil to the laminated core, and when attaching the laminated core to the frame, the possibility of interference with the jig and the device is reduced, and the productivity of the rotating electrical machine is improved.

[0032] Furthermore, according to the laminated core of Embodiment 1, the first core plate is formed such that the plate thickness increases from one side to the other side in the radial direction of the rotating electrical machine, and the second core plate is formed such that the plate thickness increases from the other side to the one side in the radial direction of the rotating electrical machine. Therefore, Furthermore, according to the manufacturing method of the laminated core of Embodiment 1 as described above, a punching step of punching the first core plate and the second core plate from an electromagnetic steel sheet having different plate thicknesses in the plate width direction, an aligning step of alternately laminating and aligning the first core plate and the second core plate in the number set in advance to form a core plate group, and a fixing step of fixing in the lamination direction of the core plate group are provided. In the punching step, the leading ends of the teeth of the first core plate and the second core plate are inverted and punched in the plate width direction of the electromagnetic steel sheet. Therefore, it is possible to surely form the first core plate with an increasing plate thickness from one side to the other side and the second core plate with an increasing plate thickness from the other side to the one side. Furthermore, the yield of the electromagnetic steel sheet can be improved.

[0033] Furthermore, according to the manufacturing method of the laminated core of Embodiment 1, in the fixing step, a part of the side surface in the lamination direction of the core plate group is adhered with an adhesive to form an adhered portion. Therefore, electrical short circuits are eliminated and residual stress can also be reduced, so that it is possible to obtain an efficient laminated core and a rotating electrical machine with suppressed generation of eddy currents and less hysteresis loss.

[0034] Furthermore, according to the method for manufacturing the laminated core of Embodiment 1, since the fixing step forms a welded portion by welding a part of the laminated core plates in the lamination direction, it is possible to obtain a laminated core and a rotating electrical machine in which the fixing between the laminations is strengthened.

[0035] Furthermore, according to the method for manufacturing the laminated core of Embodiment 1, since the fixing step fixes the core plate group by winding a coil around the core plate group, fixing of the laminated core is performed by installing a coil, so that the manufacturing process can be reduced.

[0036] Embodiment 2. In the above Embodiment 1, an example was shown in which the first core plate 11 is formed such that the plate thickness Z increases from one side (tooth tip side 64) to the other side (core back side 63) in the radial direction T2 of the rotating electrical machine 10, and the second core plate 21 is formed such that the plate thickness Z increases from the other side (core back side 63) to one side (tooth tip side 64) in the radial direction T2 of the rotating electrical machine 10. However, the present invention is not limited to this. As long as the first core plate is formed such that the plate thickness increases from one side to the other side, and the second core plate is formed such that the plate thickness increases from the other side to the one side, other examples will be described in the present Embodiment 2. Note that since other aspects are the same as those in the above Embodiment 1, the description thereof will be omitted as appropriate.

[0037] FIG. 9 is a perspective view showing the configuration of the laminated core according to Embodiment 2. FIGS. 10 and 11 are diagrams for explaining the method for manufacturing the laminated core shown in FIG. 9. FIG. 10A is a plan view of the electromagnetic steel sheet, and FIG. 10B is a diagram showing the plate thickness of the electromagnetic steel sheet as viewed from the direction of arrow W1 in FIG. 10A. FIG. 11A is a plan view showing the configuration of the first core plate, FIG. 11B is a diagram showing the plate thickness of the first core plate as viewed from the direction of arrow W4 in FIG. 11A. FIG. 11C is a plan view showing the configuration of the second core plate, and FIG. 11D is a diagram showing the plate thickness of the second core plate as viewed from the direction of arrow W5 in FIG. 11B. In the drawings, parts that are the same as those in the above Embodiment 1 are denoted by the same reference numerals and the description thereof is omitted. Also, in FIG. 9, for the sake of convenience, the plate thickness is shown to be the same.

[0038] In the second embodiment, by press working, similarly to the first embodiment, in the electromagnetic steel sheet 100 having a plate thickness deviation as shown in FIG. 10A, at different positions in the plate width direction Y, the teeth tip sides 64 of the first core plate 12 and the second core plate 22 are inverted in the rolling direction X, the first core plate 12 is punched at the first position 71, and the second core plate 22 is punched at the second position 72.

[0039] Then, the first core plate 12 punched at the first position 71 is formed as shown in FIG. 11A. And, as shown in FIG. 11B, the first core plate 12 is formed such that the plate thickness Z increases from one side to the other side in the circumferential direction T3. On the other hand, at the second position 72, the second core plate 22 punched with the teeth tip side 64 and the teeth tip side 64 of the first core plate 12 inverted is formed as shown in FIG. 11C. And, as shown in FIG. 11D, the second core plate 22 is formed such that the plate thickness Z increases from the other side to one side in the circumferential direction T3.

[0040] The first core plate 12 formed in this way is formed with an increasing plate thickness from one side to the other side, and the second core plate 22 is formed with an increasing plate thickness from the other side to one side. Note that the radial direction T2 shown in FIG. 11 indicates the direction at the center position of the circumferential direction T3 of each core plate 11, 21. And, as shown in FIG. 9, the laminated core 4 is formed by laminating the first core plate 12 and the second core plate 22 one by one alternately in the lamination direction T1.

[0041] Therefore, since the first core plate 12 with an increasing plate thickness Z on one side in the circumferential direction T3 and the second core plate 22 with an increasing plate thickness Z on the other side in the circumferential direction T3, that is, with a decreasing plate thickness Z on one side in the circumferential direction T3, are laminated in the lamination direction T1, the difference in the plate thickness Z between the first core plate 12 and the second core plate 22 is not accumulated. By appropriately combining the punching positions of the first core plate 12 and the second core plate 22, similarly to the first embodiment, the difference in the dimension in the lamination direction T1 due to the plate thickness deviation in the laminated core 4 becomes small, and a laminated core 4 with a stable posture and a small inclination and a rotating electrical machine 10 can be configured.

[0042] According to the laminated core of Embodiment 2 configured as described above, it exhibits the same effects as those of Embodiment 1 described above, and the first core plate is formed such that the plate thickness increases from one side to the other side in the circumferential direction of the rotating electrical machine, and since the second core plate is formed such that the plate thickness increases from the other side to the one side in the circumferential direction of the rotating electrical machine, furthermore, according to the method for manufacturing the laminated core of Embodiment 2 performed as described above, a punching step of punching out the first core plate and the second core plate from electromagnetic steel sheets having different plate thicknesses in the plate width direction, an alignment step of alternately laminating and aligning the first core plate and the second core plate for each preset number to form a core plate group, and a fixing step of fixing in the lamination direction of the core plate group, in the punching step, since the punching is performed with the tooth tip sides of the first core plate and the second core plate reversed in the rolling direction of the electromagnetic steel sheet, it is possible to surely form the first core plate with an increasing plate thickness from one side to the other side and the second core plate with an increasing plate thickness from the other side to the one side. Furthermore, the yield of the electromagnetic steel sheet can be improved.

[0043] Embodiment 3. In each of the above embodiments, the lamination method of the first core plates 11 and 12 and the second core plates 21 and 22 after punching is not particularly shown. However, in this Embodiment 3, the lamination method will be described. Note that since other points are the same as those in the above embodiments, the description thereof will be omitted as appropriate. In this Embodiment 3, examples of the first core plate 11 and the second core plate 21 will be described.

[0044] Generally, the shapes of the first core plate 11 and the second core plate 21 are complex shapes. For this reason, for example, as shown in FIG. 20 of the comparative example, when punching the core plate, the range of the non-punched portion becomes wide and the material yield of the electromagnetic steel sheet deteriorates.

[0045] Therefore, in the third embodiment, as shown in FIG. 12, the first core plate 11 and the second core plate 21 are punched by reversing their orientations in the electromagnetic steel sheet 100 at the first position 61 and the second position 62, respectively, to reduce the non-punched portions. As a result, the material yield of the electromagnetic steel sheet 100 can be improved. Further, since the thickness deviation of the electromagnetic steel sheet 100 is often uniform in the plate width direction Y, by reversing the punching directions of the core plates 11 and 21, two types of first core plates 11 and second core plates 21 having different thickness Z tendencies can be easily manufactured.

[0046] Next, a method for aligning the punched first core plate 11 and second core plate 21 will be described with reference to FIGS. 13 to 16. FIGS. 13 to 15 are diagrams showing a method for manufacturing a laminated core according to the third embodiment. FIG. 13A is a plan view of the electromagnetic steel sheet, FIG. 13B is a diagram showing the thickness of the electromagnetic steel sheet as viewed from the direction of arrow W1 in FIG. 13A, and FIG. 13C is a side view of each core plate punched and laminated. FIG. 14A is a plan view of the electromagnetic steel sheet, FIG. 14B is a diagram showing the thickness of the electromagnetic steel sheet as viewed from the direction of arrow W1 in FIG. 14A, and FIG. 14C is a side view of each core plate punched and laminated. FIG. 15A is a plan view of the electromagnetic steel sheet, FIG. 15B is a diagram showing the thickness of the electromagnetic steel sheet as viewed from the direction of arrow W1 in FIG. 15A, and FIG. 15C is a side view of each core plate punched and laminated. In the figures, the same parts as those in the above embodiments are denoted by the same reference numerals and the description thereof is omitted. In FIGS. 13 to 16, for the sake of convenience, the thickness is shown to be the same.

[0047] This is performed using a die 31 that can rotate in the horizontal direction Q in the plate width direction Y and the rolling direction X as shown in FIG. 14. As also shown above, since the electromagnetic steel sheet 100 is generally very thin with a thickness Z of 0.5 mm or less, it is difficult to take out the first core plate 11 and the second core plate 21 punched at different positions from the press device and stack them alternately while aligning them in the plate width direction Y.

[0048] Therefore, as shown in FIGS. 13 to 15, the die 31 is rotated 180 degrees in the horizontal direction Q in the rolling direction X and the plate width direction Y at regular intervals in synchronization with punching by the press device, and the first core plate 11 and the second core plate 21 punched at different positions in the plate width direction Y are aligned while being alternately laminated in the die 31.

[0049] Specifically, first, as shown in FIG. 13A, the electromagnetic steel sheet 100 is punched in a state where the die 31 is arranged at a preset position. Here, in one press, the first core plate 11 is punched at the first position 61 and the second core plate 21 is punched at the second position 62 simultaneously. Then, after pressing five times, as shown in FIG. 13C, five first core plates 11 and five second core plates 21 are aligned and laminated in the lamination direction T1 in the die 31.

[0050] Next, when the number of laminated first core plates 11 and second core plates 21 is preset to five, as shown in FIG. 14A, the die 31 is rotated 180 degrees in the horizontal direction Q. Then, as shown in FIG. 14C, five second core plates 21 aligned and laminated under the first position 61 are arranged, and five first core plates 11 aligned and laminated under the second position 62 are installed.

[0051] In this state, again, as shown in FIG. 15A, by punching the electromagnetic steel sheet 100, as shown in FIG. 15C, the first core plate 11 punched at the first position 61 is aligned and laminated on the five second core plates 21 aligned and laminated. Also, the second core plate 21 punched at the second position 62 is aligned and laminated on the five first core plates 11 aligned and laminated.

[0052] If the above operation is repeated for each preset number of punching operations, here, for every five preset laminated sheets of the first core plate 11 and the second core plate 21, as shown in FIG. 16, a core plate group 400 composed of the first core plate 11 and the second core plate 21 is formed. The core plate group 400 formed in this way can be taken out while being aligned by the die 31, and it is possible to reduce the time and cost required for the alignment process.

[0053] Also, although it is conceivable to take out the core plate group 400 as the core plate group 40 from the die 31 when the required number of core plates for the laminated core 4 is stacked, it is not limited to this. As shown in FIG. 16, it is also conceivable to take out the core plate group 400 in a state where it is stacked in a number more than the required number for the laminated core 4 from the die 31, and after taking it out, divide it into the core plate group 40 corresponding to the required number of the laminated core 4 for manufacturing. In that case, further time and cost can be reduced.

[0054] According to the method for manufacturing a laminated core of Embodiment 3 performed as described above, In the alignment step, in synchronization with the punching step, at least one of the first core plate or the second core plate is laminated in a preset number. When the preset number is laminated, it is rotated 180 degrees in the horizontal direction, and the second core plate or the first core plate different from the laminated first core plate or second core plate is laminated and aligned to form the core plate group. Therefore, The first core plate and the second core plate can be continuously and easily aligned and laminated without being taken out during the punching step, so the productivity is improved. In addition, the number of steps can be reduced, the time required for manufacturing is shortened, and the productivity is improved.

[0055] Embodiment 4. In each of the above embodiments, the aligning device for the first core plates 11 and 12 and the second core plates 21 and 22 after punching is not particularly shown. However, in this Embodiment 4, the aligning device will be described. Note that since other points are the same as those in the above embodiments, the description thereof will be omitted as appropriate. Also, in this Embodiment 4, examples of the first core plate 11 and the second core plate 21 will be described.

[0056] FIG. 17 is a diagram showing the configuration of the laminated core aligning device according to the fourth embodiment. FIG. 18 is a diagram showing the configuration of another laminated core aligning device according to the fourth embodiment. In the figures, parts similar to those in the above-described embodiments are denoted by the same reference numerals and description thereof is omitted. In FIGS. 17 and 18, for convenience, the plate thickness is shown to be the same.

[0057] As shown in FIG. 17, the aligning device 32 includes a conveyance lane 331 that conveys the first core plate 11 downward in the paper surface, a conveyance lane 332 that conveys the second core plate 21 downward in the paper surface, an aligning lane 34 that aligns the core plates 11 and 21 and discharges them as a core plate group 40, a stopper 351 that stops the first core plate 11 at a certain position on the conveyance lane 331, a stopper 352 that stops the second core plate 21 at a certain position on the conveyance lane 332, a transfer block 361 that transfers the first core plate 11 from the conveyance lane 331 to the aligning lane 34, a transfer block 362 that transfers the second core plate 21 from the conveyance lane 332 to the aligning lane 34, and a discharge block 37 that pushes out the core plate group 40 formed in the aligning lane 34 in the discharge direction.

[0058] Next, a procedure for aligning the core plates 11 and 21 by the aligning device 32 of the fourth embodiment configured as described above will be described. First, a plurality of punched first core plates 11 are inserted from above the paper surface of the conveyance lane 331, and the tips are applied to the stopper 351. Similarly, a plurality of second core plates 21 are inserted into the conveyance lane 332, and the tips are applied to the stopper 352.

[0059] Next, with a plurality of first core plates 11 on the transfer lane 331 pressed against the stopper 351, the transfer block 361 is moved toward the alignment lane 34 to transfer the first core plates 11 to the alignment lane 34. Next, the discharge block 37 is moved downward in the drawing plane to move the plurality of first core plates 11 downward in the drawing plane. Thereafter, with the second core plates 21 on the transfer lane 332 pressed against the stopper 352, the transfer block 362 is moved toward the alignment lane 34 to transfer the second core plates 21 to the alignment lane 34. Next, the discharge block 37 is moved downward in the drawing plane to move the plurality of second core plates 21 downward in the drawing plane. By repeating this operation, a core plate group 40 in which the first core plates 11 and the second core plates 21 are alternately stacked can be manufactured for every fixed number of sheets.

[0060] Also, as another example, the core plate group 40 may be manufactured using an alignment block 38 as shown in FIG. 18. The first core plates 11 are loaded into the inlet 681 of the alignment block 38, and the second core plates 21 are loaded into the inlet 682. The core plates 11 and 21 loaded from the respective inlets 681 and 682 are alternately stacked at the joint portion 69, and at the outlet 70, a core plate group 40 in which the first core plates 11 and the second core plates 21 are alternately stacked is obtained. By using such an alignment block 38, the core plate group 40 can be manufactured with a simpler structure compared to the alignment device 32 shown above, and there is an effect of reducing the device cost and improving the productivity.

[0061] According to the method for manufacturing a laminated core of the fourth embodiment performed as described above, it has the same effect as the third embodiment described above, and in the alignment step, the first core plate and the second core plate are respectively loaded into different inlets, and by the time they reach the outlet where the first core plate and the second core plate merge, the directions of the tip sides of the teeth of the first core plate and the second core plate are aligned to form the core plate group, the directions of the first core plate and the second core plate can be easily aligned.

[0062] In FIG. 18 of the above-described Embodiment 4, the description was limited to a conceptual example of a method of aligning the first core plate 11 and the second core plate 21 in a single row. However, in Embodiment 5 and Embodiment 6 described below, more specific examples will be described. Note that since other points are the same as those in the above-described embodiments, the description thereof will be omitted as appropriate.

[0063] Embodiment 5. FIG. 21 is a diagram showing the configuration of a press device according to Embodiment 5. FIG. 22 is a diagram showing the configuration of a stacking core aligning device according to Embodiment 5. FIG. 23 is a plan view showing the state of the first core plate and the second core plate at the K1-K1 position of the aligning device shown in FIG. 22. FIG. 24 is a plan view showing the state of the first core plate and the second core plate at the K2-K2 position of the aligning device shown in FIG. 22. FIG. 25 is a plan view showing the state of the first core plate and the second core plate at the K3-K3 position of the aligning device shown in FIG. 22. FIG. 26 is a plan view showing the state of the first core plate and the second core plate at the K4-K4 position of the aligning device shown in FIG. 22. FIG. 27 is a plan view showing the state of the first core plate and the second core plate at the K5-K5 position of the aligning device shown in FIG. 22. FIG. 28 is a plan view showing the state of the first core plate and the second core plate at the K6-K6 position of the aligning device shown in FIG. 22. In the figures, the same parts as those in the above-described embodiments are denoted by the same reference numerals and the description thereof is omitted.

[0064] As shown in FIG. 21, the press device 50 feeds a ribbon-shaped electromagnetic steel sheet 100 to the mounted die 51 and punches out the first core plate 11 and the second core plate 21. The punched first core plate 11 and second core plate 21 are repeatedly punched and fed downward in the die 51. Then, the feeding direction of each core plate 11, 21 is bent and fed forward on the paper surface. Note that, without bending the advancing direction of each core plate 11, 21, an aligning device for aligning the first core plate 11 and the second core plate 21 in a single row, which will be described next, may be disposed directly below the die 51.

[0065] As shown in Fig. 22, the aligning device 320 feeds the first core plate 11 and the second core plate 21 into different inlets respectively, and aligns the directions of the tooth tip sides 64 of the first core plate 11 and the second core plate 21 to form a core plate group 40 before they merge at the outlet. Then, the first core plate 11 and the second core plate 21 discharged from the press device 50 have an "alignment section H1" for aligning the directions of the tooth tip sides 64 of the first core plate 11 and the second core plate 21, and a "merging section H2" for aligning the first core plate 11 and the second core plate 21 in a row.

[0066] The alignment section H1 is provided with a linear guide 521 and a spiral guide 522, and the merging section H2 is provided with a side guide 523, a tip guide 524, a first gear 531, and a second gear 532 (see Figs. 26 to 28). The merging section H2 has a curved portion 91, an overlapping portion 92, and an alignment portion 93. Details of each part will be described later.

[0067] The linear guide 521 pressure-feeds and guides the first core plate 11 in a fixed direction while supporting it. The spiral guide 522 pressure-feeds and guides the second core plate 21 while rotating its direction. The side guide 523 guides the tooth sides 65 of each core plate 11, 21. The tip guide 524 guides the tooth tip sides 64 of each core plate 11, 21. The first gear 531 and the second gear 532 stack each core plate 11, 21 in a preset number.

[0068] Next, a method for aligning the first core plate 11 and the second core plate 21 discharged from the press device 50 in a row using the aligning device 320 configured as described above will be described. First, in the orientation alignment section H1, as shown in FIGS. 22 and 23, the initial first core plate 11 and the second core plate 21 introduced into the aligning device 320 face in opposite directions at the tooth tip side 64. Then, the first core plate 11 is passed while maintaining a constant orientation by the linear guide 521, and the second core plate 21 is passed while rotating its orientation by the spiral guide 522. Then, as shown in FIGS. 22 and 24, the second core plate 21 rotates its orientation, and finally, as shown in FIGS. 22 and 25, the orientations of the first core plate 11 and the second core plate 21 are aligned, and the orientations of the tooth tip sides 64 of the first core plate 11 and the second core plate 21 are aligned.

[0069] Here, an example in which the orientation of the second core plate 21 is rotated to align the orientations of the tooth tip sides 64 of the first core plate 11 and the second core plate 21 is shown, but the present invention is not limited to this. The orientation of the first core plate 11 may be rotated, or the orientations of both the first core plate 11 and the second core plate 21 may be rotated to align the orientations of the tooth tip sides 64 of the first core plate 11 and the second core plate 21.

[0070] Here, an example of a pressure feed guide composed of two spiral guides 522 is shown, but the present invention is not limited to this. When one is a linear guide and spiral guides are arranged around it, it is possible to rotate the orientation of the core plate in the same manner as the two spiral guides 522. Further, a helical groove may be formed on the side surface of a cylinder, or a helical notch groove may be formed in a cylinder to form a path for rotating the orientation of the core plate. Furthermore, a path may be formed by using a 3D printer or the like to form a helical hole having substantially the same shape as the core plate shape.

[0071] Next, passing through the alignment section H1, the first core plate 11 and the second core plate 21 with the aligned directions on the tooth tip side 64 enter the merging section H2. As shown in FIGS. 22 and 26, the first core plate 11 and the second core plate 21 are composed of three plates, and the side guide 523 that guides the tooth side surface 65 and the tip guide 524 that guides the tooth tip side 64 guide the pressure feeding of each core plate 11, 12. The merging section H2 is composed of a path including a curved portion 91, an overlapping portion 92, and an alignment portion 93, and the roles of each will be described. In the curved portion 91, while bringing the first core plate 11 and the second core plate 21 closer to each other, a gap is formed between the stacked core plates 11, 21. That is, since the outer peripheral side track is longer than the inner peripheral side of the path of the curved portion 91, a gap is formed between the core plates 11, 21 on the outer side of the curved portion 91.

[0072] Next, as shown in FIGS. 22 and 27, in the overlapping portion 92, it is composed of a path for bringing the first core plate 11 and the second core plate 21 closer and the first gear 531 and the second gear 532. The first gear 531 is arranged close to the first core plate 11, and the second gear 532 is arranged close to the second core plate 21. The first gear 531 and the second gear 532 are fixed in a state where they are rotatable on the same axis and the phase is shifted by half the pitch. The tooth tip of the first gear 531 engages with every one or several of the first core plate 11 in the stacking direction gap formed in the first core plate 11 that has passed through the curved portion 91, and rotates in conjunction with the pressure feeding of the first core plate 11. Similarly, the tooth tip of the second gear 532 engages with every one or several of the second core plate 21 in the stacking direction gap formed in the second core plate 21 that has passed through the curved portion 91, and rotates in conjunction with the pressure feeding of the second core plate 21.

[0073] Since these first gear 531 and second gear 532 rotate while being fixed to the same axis in a state where the phases are shifted by half the pitch, each core plate 11, 21 is sent to the next alignment portion 93 one by one or several at a time alternately. That is, by the first gear 531 and the second gear 532, the first core plate 11 and the second core plate 21 can be stacked one by one or several at a time alternately without colliding with each other. Note that these gears 531, 532 may be rotated by power from an external motor or the like, or may be rotated by the pressure feeding of each core plate 11, 21.

[0074] Next, as shown in FIGS. 22 and 28, in the alignment portion 93, from the state where the first core plate 11 and the second core plate 21 are stacked one core or several cores at a time, the width of the path is gradually narrowed, the first core plate 11 and the second core plate 21 are aligned to manufacture the core plate group 40, and it is sent to the next fixing process. Also, if a plurality of these devices are connected, it is also possible to first align the four rows of core plates into two rows, and further align them from two rows to one row.

[0075] According to the method for manufacturing a laminated core of Embodiment 5 performed as described above, it has the same effects as the above-described embodiments, and in the alignment process, since the first core plate and the second core plate with the same direction at the tooth tip side are alternately stacked by gears to form the core plate group, the first core plate and the second core plate can be alternately stacked by gears without colliding with each other.

[0076] Furthermore, according to the method for manufacturing a laminated core of Embodiment 5, in the alignment process, the core plate group is formed by aligning the directions of the first core plate and the second core plate at the tooth tip side in either one of the directions of the first core plate or the second core plate at the tooth tip side punched in the punching process, it is possible to align the directions of the first core plate and the second core plate at the tooth tip side without requiring a complicated operation.

[0077] Furthermore, according to the method for manufacturing the laminated core of Embodiment 5, in the alignment step, the first core plate and the second core plate punched in the punching step are aligned with respect to the direction of the tip sides of the teeth of the first core plate and the second core plate, which is different from the direction of the tip sides of the teeth of the first core plate and the second core plate, to form the core plate group. Therefore, it is possible to align the directions of the tip sides of the teeth of the first core plate and the second core plate without requiring complicated operations.

[0078] Embodiment 6. In the present Embodiment 6, a method for aligning the first core plate 11 and the second core plate 21 in a row in a manner different from that of Embodiment 5 will be described. Note that since other points are the same as those in the above-described embodiments, the description thereof will be omitted as appropriate.

[0079] FIG. 29 is a diagram showing the configuration of an alignment device for a laminated core according to Embodiment 6. FIG. 30 is a plan view showing the configuration of a rotating disk as viewed from the direction of line K-K of the alignment device shown in FIG. 29. In the drawings, parts the same as those in the above-described embodiments are denoted by the same reference numerals and the description thereof is omitted. As shown in FIG. 29, the alignment device 321 aligns the first core plate 11 and the second core plate 21 discharged from the press device 50 with respect to the direction of the tip sides 64 of the teeth of the first core plate 11 and the second core plate 21 and aligns them in a row. The alignment device 321 includes a first guide 571, a second guide 572, a rotating disk 55, a pusher 56, and an outlet guide 573.

[0080] The first guide 571 is formed to communicate with the path of the first core plate 11 pumped from the press device 50. The second guide 572 is formed to communicate with the path of the second core plate 21. As shown in Fig. 30, the rotating disk 55 is arranged at 90-degree intervals with the center of rotation O as the center, based on 0 degrees shown in the figure, and through holes 551, 552, 553, and 554 are provided at four locations, which are formed in the same shape as each core plate 11, 21. Assuming the position of the through hole 551 at the current time is 0 degrees, there is a through hole 552 at a position 90 degrees counterclockwise, a through hole 553 at a position 180 degrees, and a through hole 554 at a position 270 degrees. That is, three or more through holes 551 to 554 are formed at positions equally distributed with respect to the center O, here at four locations.

[0081] Also, the rotating disk 55 is connected to an actuator such as a servo motor, either directly or via a belt and gears, and is formed to be rotatable. In the sixth embodiment, an example in which the rotating disk 55 is formed in a circular shape is shown, but it is not limited to this. As long as the arrangement relationship of each through hole and the movement of each through hole can be performed in the same way, a rotating plate that is not limited to a circular shape is also possible.

[0082] Also, the positional relationship between the first core plate 11 in the first guide 571 and the second core plate 21 in the second guide 572 is arranged such that when the first core plate 11 is rotated 180 degrees around the center O of the rotating disk 55, it overlaps with the second core plate 21. In other words, the paths of the first core plate 11 and the second core plate 21 are in a positional relationship where they rotate and coincide by an angle obtained by dividing 360 degrees by 2 or more, here an integer of 2, which is 180 degrees. In the state of Fig. 30, the through hole 551 at the 0-degree position is connected to the first guide 571, and the through hole 553 at the 180-degree position is connected to the second guide 572. Further, a pusher 56 is arranged at the through hole 554 at the 270-degree position, and an outlet guide 573 is connected to the opposite side. The pusher 56 is connected to an actuator such as a linear servo motor and is formed to be linearly movable.

[0083] Next, the interlocking operation of the rotating disk 55, the pusher 56, and the press device 50 of the aligning device 321 configured as described above will be described. The rotating disk 55 is interlocked with the press device 50 and rotates counterclockwise (in the direction of the arrow in FIG. 30) by 90 degrees at the timing when the press device 50 punches each core plate 11, 21 for each stroke or every certain plurality of strokes. In other words, it rotates by an angle obtained by dividing 360 degrees by an integer of 2 or more, here 2, and further by an angle obtained by dividing 180 degrees by an integer of 1 or more, here 2, which is 90 degrees. The pusher 56 makes a reciprocating linear motion to a certain position at the timing when the rotating disk 55 is not rotating, that is, at the timing substantially coinciding with the punching of each core plate 11, 21 by the press device 50.

[0084] Regarding the case where the rotating disk 55 is rotated for each stroke in the above interlocking operation, the process of aligning the first core plate 11 and the second core plate 21 in a row will be described by paying attention to the through hole 551. In the state shown in FIG. 30, when each core plate 11, 21 is punched by the press device 50, it is at the 0-degree position, and one first core plate 11 is inserted into the through hole 551 connected to the first guide 571. Let this punching be the Nth time. Between this Nth punching and the next (N + 1)th punching, the rotating disk 55 rotates, and the through hole 551 containing one first core plate 11 moves to the 90-degree position.

[0085] In this (N + 1)th punching, since the first guide 571 is not connected to the through hole 551, there is no change from the state where one first core plate 11 is in the through hole 551. At the next (N + 2)th punching, the through hole 551 rotates and moves to the 180-degree position and is connected to the second guide 572, so one second core plate 21 is inserted. That is, at this time, one first core plate 11 and one second core plate 21 are in the through hole 551.

[0086] At the next (N + 3)-th punching, the through-hole 551 rotates and moves to the 270-degree position. By the pusher 56, a total of two core plates, one first core plate 11 and one second core plate 21, are sent to the outlet guide 573, and the through-hole 551 is in a state where no core plate is inserted. At the next (N + 4)-th punching, the through-hole 551 rotates and moves to the 0-degree position, returns to the state at the N-th punching, and the above operations are repeated.

[0087] Although only the through-hole 551 has been described here, for the other through-holes 552 to 554, each performs the same operation as the through-hole 551. Therefore, for each stroke of the press device 50, a total of two core plates, one first core plate 11 and one second core plate 21, are sent to the outlet guide 573, and the core plate group 40 in which the first core plate 11 and the second core plate 21 are alternately laminated is aligned and sent to the next fixing process. In the above description, the case where the rotating disk 55 rotates for each stroke has been described. However, when the rotating disk 55 rotates for a certain plurality of strokes, the core plate group 40 in which a plurality of core plates are alternately laminated for each multiple is aligned.

[0088] As shown in the sixth embodiment above, since it is not necessary to rotate the core plate itself to align the directions of the tooth tips, for example, the first core plate 11 and the second core plate 21 punched in the arrangement as shown in FIG. 4 can be alternately overlapped to align the core plate group 40, and it can also be arranged directly below the mold 51. Further, when arranged directly below the mold 51, if the pusher 56 is directly connected to the press device 50 and configured such that the pusher 56 moves linearly in conjunction with the punching operation, the actuator for driving the pusher 56 can be made unnecessary.

[0089] Further, according to the sixth embodiment of the present invention, as shown in FIGS. 13 to 15 of the third embodiment above, it is possible to cope with this by rotating the rotating disk 55 without rotating the die 31 as a guide. Therefore, the load of rotation can be reduced and the operation speed of rotation can be increased. Further, in the sixth embodiment of the present invention, instead of the transfer blocks 361 and 362 that push and transfer as shown in FIG. 17 of the fourth embodiment above, since the rotating disk 55 is used, the directions of the core plates 11 and 12 having different directions can be aligned while holding each core plate 11 and 21.

[0090] Also, although a method of aligning two core plates, i.e., the first core plate 11 and the second core plate 21, in a row has been shown here, it is not limited to this. By using the method of Embodiment 6, it is possible to align more core plates in a row at once. For example, when aligning four core plates in a row, five through-holes are arranged in the rotating disk at intervals of 72 degrees. Four guides are connected to the positions of four of the five through-holes, and a pusher and an outlet guide are arranged at the position of the remaining one through-hole. By rotating the rotating disk every 72 degrees and moving the pusher linearly, it becomes possible to align the four core plates in a row.

[0091] According to the method for manufacturing a laminated core of Embodiment 6 performed as described above, it has the same effects as the above-described embodiments, and the alignment step is such that a rotating plate having through-holes for accommodating the first core plate and the second core plate, which rotates around the center of rotational movement and connects to the paths of the first core plate and the second core plate punched in the punching step, rotates by an angle corresponding to the through-holes in the paths of the first core plate and the second core plate in synchronization with the punching step, and houses and laminates the first core plate and the second core plate in the through-holes of the rotating plate, and since the rotating plate discharges the laminated first core plate and second core plate from the through-holes of the rotating plate at an angle where the paths of the first core plate and the second core plate are not connected by the through-holes to form the core plate group, the load of rotation can be reduced and the operating speed of rotation can be increased, so productivity is improved.

[0092] Furthermore, according to the method for manufacturing a laminated core of Embodiment 6, the alignment step is such that when the paths of the first core plate and the second core plate are in a positional relationship where they coincide after rotating and moving by an angle obtained by dividing 360 degrees by an integer of 2 or more, The rotating plate having three or more through-holes equally distributed with respect to the center is Synchronized with the punching process, the rotating plate is rotated by an angle obtained by further dividing the 360 degrees by an integer of 2 or more and then by an integer of 1 or more, and the first core plate and the second core plate are laminated in the through-hole of the rotating plate, so The load of rotation can be further reduced, and the productivity can be surely improved.

[0093] Embodiment 7. In each of the above embodiments, an example of the laminated core 4 formed of two types of core plates with different plate thicknesses of the first core plates 11 and 12 and the second core plates 21 and 22 has been shown, but the present invention is not limited thereto, and it is also possible to form a laminated core with three or more types of core plates having different plate thicknesses, which will be described in Embodiment 7 of the present invention. Note that since it is the same as the above embodiments except for using three or more types of core plates with different plate thicknesses, the description thereof will be omitted as appropriate.

[0094] As shown in FIG. 19, in the electromagnetic steel sheet 100, core plates are punched at different positions in the plate width direction Y. The relationship among the rolling direction X, the plate width direction Y, and the plate thickness Z in the electromagnetic steel sheet 100 is the same as that in the above embodiments. Here, punching is simultaneously performed in four rows at different first positions 81, second positions 82, third positions 83, and fourth positions 84 in the plate width direction Y. For this reason, four types of core plates with different plate thicknesses are simultaneously formed. Then, the four types of core plates with different plate thicknesses are laminated for each preset number to form a laminated core.

[0095] Manufactured in this way, different from the above embodiments, a large number of core plates can be punched at once, the number of production sheets per unit time increases, and the productivity can be improved. Further, if the plate thickness Z in the plate width direction Y is measured in advance to obtain the profile of the plate thickness Z, a combination of the lamination directions of a plurality of types of core plates with different plate thicknesses that can minimize the plate thickness deviation of the laminated core when laminated alternately can be selected.

[0096] Therefore, compared with the case of alternately laminating only two types of core plates, the possibility of reducing the plate thickness deviation is increased, and the laminated core 4 that constitutes the efficient rotating electrical machine 10 can be manufactured. Further, since the combination for laminating can be changed corresponding to the state of the plate thickness of the electromagnetic steel sheet 100 which is the material, it becomes easy to cope with disturbances such as changes in material lots and climate fluctuations, and the quality of the manufactured laminated core 4 is stabilized and the productivity is improved.

[0097] According to the method for manufacturing a laminated core performed as described above, A method for manufacturing a laminated core formed by laminating a plurality of core plates punched from an electromagnetic steel sheet having different plate thicknesses in the plate width direction, A punching step of simultaneously punching a plurality of the core plates at different positions in the plate width direction of the electromagnetic steel sheet to form a plurality of types of core plates having different plate thicknesses; An aligning step of laminating and aligning a plurality of types of the core plates in a preset order and for each number to form a core plate group; Since it includes a fixing step of fixing the core plate group in the lamination direction, By using a plurality of types of core plates having different plate thicknesses, it is possible to obtain a laminated core, a rotating electrical machine, a method for manufacturing a laminated core, and a method for manufacturing a rotating electrical machine that can be produced inexpensively and stably.

[0098] Although various exemplary embodiments and examples are described in the present application, the various features, aspects, and functions described in one or more of the embodiments are not limited to the application of a specific embodiment, but are applicable to the embodiments alone or in various combinations. Therefore, countless variations not illustrated are assumed within the scope of the technology disclosed in the present application. For example, it includes the case of deforming, adding, or omitting at least one component, and further, the case of extracting at least one component and combining it with the components of other embodiments.

Description of Reference Numerals

[0099] 10 Rotating electrical machine, 122 Rotor, 123 Stator, 124 Frame, 100 Electromagnetic steel sheet, 107 Air gap, 11 First core plate, 12 First core plate, 21 Second core plate, 22 Second core plate, 4 Laminated core, 5 Adhesive part, 8 Welded part, 9 Coil, 31 Die, 32 Alignment device, 320 Alignment device, 321 Alignment device, 331 Conveyor lane, 332 Conveyor lane, 34 Alignment lane, 351 Stopper, 352 Stopper, 361 Transfer block, 362 Transfer block, 37 Discharge block, 38 Alignment block, 40 Core plate group, 50 Press device, 51 Mold, 521 Linear guide, 522 Spiral guide, 531 First gear, 532 Second gear, 55 Rotating disc, 551 Through hole, 552 Through hole, 553 Through hole, 554 Through hole, 56 Pusher, 571 First guide, 572 Second guide, 573 Exit guide, 61 First position, 62 Second position, 63 Core back side, 64 Tooth tip side, 681 Entrance, 69 Coupling part, 70 Exit, 71 First position, 72 Second position, 81 First position, 82 Second position, 83 Third position, 84 Fourth position, 91 Curved part, 92 Overlapping part, 93 Alignment part, O Center, T1 Lamination direction, T1 Axial direction, T2 Radial direction, T3 Circumferential direction, X Rolling direction, Y Plate width direction, Z Plate thickness.

Claims

1. A method for manufacturing a laminated core formed by laminating a plurality of first core plates and second core plates punched from electromagnetic steel sheets, The first core plate is formed such that the plate thickness increases from one side to the other side, The second core plate is formed such that the plate thickness increases from the other side to the one side, The first core plate and the second core plate are alternately laminated for each preset number to form the laminated core, A punching step of punching the first core plate and the second core plate from an electromagnetic steel sheet having different plate thicknesses in the plate width direction, An alignment step of alternately laminating the first core plate and the second core plate for each preset number to form an aligned core plate group, And a fixing step of fixing in the lamination direction of the core plate group, In the punching step, in the method for manufacturing a laminated core, the teeth tip sides of the first core plate and the second core plate are inverted and punched in the plate width direction of the electromagnetic steel sheet, or the teeth tip sides of the first core plate and the second core plate are inverted and punched in the rolling direction of the electromagnetic steel sheet, In the alignment step, the first core plate and the second core plate are respectively fed into different inlets, and until the outlet where the first core plate and the second core plate merge, the teeth tip sides of the first core plate and the second core plate are aligned to form the core plate group.

2. The method for manufacturing a laminated core according to claim 1, wherein in the alignment step, the first core plate and the second core plate with the aligned teeth tip sides are alternately laminated by gears to form the core plate group.

3. The method for manufacturing a laminated core according to claim 1 or claim 2, wherein in the alignment step, the teeth tip sides of the first core plate and the second core plate are aligned in either one of the directions of the teeth tip sides of the first core plate or the second core plate punched in the punching step to form the core plate group.

4. The alignment step is the method for manufacturing a laminated core according to claim 1 or claim 2, wherein the first core plate and the second core plate punched in the punching step are aligned in a direction different from the direction of the teeth tip sides of the first core plate and the second core plate to form the core plate group.

5. A method for manufacturing a laminated core formed by laminating a plurality of first core plates and second core plates punched from electromagnetic steel sheets, The first core plate is formed such that the plate thickness increases from one side to the other side, The second core plate is formed such that the plate thickness increases from the other side to the one side, The first core plate and the second core plate are alternately laminated for each preset number to form the core plate group, A punching step of punching the first core plate and the second core plate from electromagnetic steel sheets having different plate thicknesses in the plate width direction, An alignment step of alternately laminating the first core plate and the second core plate for each preset number to form an aligned core plate group, And a fixing step of fixing in the lamination direction of the core plate group, In the punching step, in the method for manufacturing a laminated core, the teeth tip sides of the first core plate and the second core plate are inverted and punched in the plate width direction of the electromagnetic steel sheet, or the teeth tip sides of the first core plate and the second core plate are inverted and punched in the rolling direction of the electromagnetic steel sheet, The alignment step is, A rotating plate having a through hole that rotates around a rotation movement center and connects to the paths of the first core plate and the second core plate punched in the punching step to accommodate the first core plate and the second core plate, Synchronized with the punching step, the rotating plate rotates by an angle corresponding to the through hole in the paths of the first core plate and the second core plate, and the first core plate and the second core plate are stored and laminated in the through hole of the rotating plate. A method for manufacturing a laminated core that forms a core plate group by discharging the laminated first core plate and second core plate from the through hole of the rotary plate at an angle where the paths of the first core plate and the second core plate are not connected by the through hole.

6. The alignment step is When the paths of the first core plate and the second core plate are rotationally moved by an angle obtained by dividing 360 degrees by an integer of 2 or more and are in a positional relationship where they coincide, The rotary plate having three or more through holes arranged at equal positions with respect to the center The method for manufacturing a laminated core according to claim 5, wherein, in synchronization with the punching step, the rotary plate is rotated by an angle obtained by further dividing the angle obtained by dividing 360 degrees by an integer of 2 or more by an integer of 1 or more, and the first core plate and the second core plate are laminated in the through hole of the rotary plate.

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